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5/1/19
1
Water Treatment Boot Camp
May 1, 2019
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2
Today’sTopics:
Water Overview
Pre-treatment & Filtration Options
Cooling Towers
Steam Boilers
Water Testing Techniques
Troubleshooting & Corrective Actions
Equipment & Reporting
WATEROVERVIEWFactsIndustrial usesCharacteristics
Presenter:Rob PierickSenior Territory Manager
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Basic Water Characteristics
City of Waterloo Water Well Water
p Alkalinity (mg/L as CaCO3) 0 0
m Alkalinity (mg/L as CaCO3) 214 331
Chloride (mg/L as Cl-) 27.4 13.8
Silica (mg/L as SiO2) 17.4 35.7
Sulfate (mg/L as SO42-) 30.5 819
Ortho-Phosphate (mg/L as PO43-) < 0.1 < 0.1
Total Phosphate (mg/L as PO43-) < 1.6 < 1.6
Calcium (mg/L as Ca2+) 75.8 267
Magnesium (mg/L as Mg2+) 23.0 81.6
Calcium Hardness (mg/L as CaCO3) 190 668
Magnesium Hardness (mg/L as CaCO3) 94.3 335
Total Hardness (mg/L as CaCO3) 284 1003
Iron, Total (mg/L as Fe) < 0.1 1.8
Copper (mg/L as Cu) < 0.1 < 0.1
Sodium (mg/L as Na+) 10.4 159
Potassium (mg/L as K+) 1.2 8.8
pH 7.9 7.7
Conductivity 605 1950
Comparative example of surface and ground water characteristics
WATER OVERVIEW | Water Treatment Boot Camp 4
Why all the fuss?
WATER OVERVIEW | Water Treatment Boot Camp
Boilers will explode with improper water treatment/management
Premature equipment failures and unscheduled downtime will result if water systems are not properly maintained and chemically treated.
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Water QualityLater we will discuss why it is important to maintain consistent good high-quality water based on industry standards:
• ASME – American Society of Mechanical Engineers
• ABMA – American Boiler Manufacturers Association
• CTI – Cooling Technology Institute
WATER OVERVIEW | Water Treatment Boot Camp 6
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Pretreatment & Filtration Options
Presenter: Jeff Freitag – Director of Sales
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Why Pretreat?• Consistency of water quality
• Make-up sources and quality vary
• Chemicals can only do so much
• Needed for almost all applications
• Prevent against scaling, deposition and improved efficiencies
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 8
Most Common Treatment Methods
Filtration Softening Reverse Osmosis
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 9
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Filtration
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 10
A process for separating suspended and colloidal impurities from water• Passage through a bed of granular media• Passage through spiral wound cartridge or bag.
Bag and Cartridge FiltersAdvantages / Disadvantages
ADVANTAGESLow capital cost, simple operation
DISADVANTAGESHigh operating cost, labor intensive
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 11
Media Filters
ADVANTAGES• Fine Filtration• 15 microns
• Automatic Operation• M inimal labor
• Large surface area
DISADVANTAGES• Moderate cap. Cost
• High backwash vol.• Great “bug” trap / media
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 12
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Tekleen Self-Cleaning Filtration• Automatically self-cleans using only
water pressure
• High performance screens• Flow is not interrupted during cleaning
process – means no downtime• External power is not required• Virtually Maintenance free
• Easy to install• Configurable to a wide range of
applications
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 13
Key Takeaways – Filters• Make sure not to exceed maximum pressure drop of
15 psig before changing out any type of cartridge bag filter• Track inlet and outlet pressures
• Track pressure differentials across media filters to ensure that they are backwashing properly.
• Media filters may need to be disinfected on a annual or semi annual basis to remove microbiological fouling.• Use fresh water for backwash filters instead of process or tower water.
• Automatic screen/disc filters are a good alternative to media filters as they use less water to backwash
KEYTAKEAWAYS
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 14
Softeners• Remove calcium, manganese
and iron
• What information do you need to know when sizing softeners?
• Commercial units regenerate just like the unit in your house (multiple designs)
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 15
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Ion Exchange Resin
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 16
Hard water loaded with Calcium, Magnesium and many other ions enters the softener coming in contact with millions of resin beads holding billions of sodium ions.
The Calcium, Magnesium and other ions trade places with the Sodium ions creating softened water.
How do you know the softener is working?• Perform a total hardness test on the water.• Soft water used for boiler make up should have <0.5 ppm of total
hardness. This will vary depending upon boiler pressure. As pressure goes up acceptable hardness levels go down.• Soft water used for cooling tower make up should be less than 50
ppm as a rule of thumb. This will go down as the cycles of concentration in the tower go up.
17PRETREATMENT & FILTRATION | Water Treatment Boot Camp
Key Takeaways – Softeners
• Soft water is critical to pretreatment and management of heat exchange systems
• Monitor salt usage and make sure there is salt in your brine tank
• Clean your brine tank
• Brine elusion studies will help determine efficiencies• Contact your water treater for this service
KEYTAKEAWAYS
PRETREATMENT & FILTRATION | Water Treatment Boot Camp 18
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19PRETREATMENT & FILTRATION | Water Treatment Boot Camp
• Dealkalizer for alkalinity reduction
• Demineralizer for removal of both anions and cations
Dealkalizers and Demineralizer
Reverse Osmosis
20PRETREATMENT & FILTRATION | Water Treatment Boot Camp
• Membrane -based separation process
• Involves the separation of dissolved solids from the feedwater by means of a semi-permeable membrane• Membranes allow water to pass
through (permeate) readily, but are fairly impermeable to other constituents in the feed stream.
Reverse Osmosis
21PRETREATMENT & FILTRATION | Water Treatment Boot Camp
• What are the benefits to using RO water for boiler feed water?
• Cycles of concentration
• Better water quality (Total dissolved solids and alkalinity reduction) = better water quality
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Semipermeable Membranes
22PRETREATMENT & FILTRATION | Water Treatment Boot Camp
Chemical Treatment• RO feedwater must be carefully prepared to minimize suspended solids, scaling ions, free
halogen residuals and microbiological contamination.
• Feedwater should then be chemically treated to prevent mineral scaling, plugging and microbiological degradation of the membranes.
• Concentrate can be tested for amount of RO antiscalant present to prevent overfeed or underfeed of product.
23PRETREATMENT & FILTRATION | Water Treatment Boot Camp
Key Takeaways – ROs• Make-up water quality is critical
• Monitor concentrate and permeate flow and pressure
• Reduction of alkalinity and conductivity greatly increase cycles of concentration
• Permeate water must be treated to prevent corrosion and biological growth
• Soft water vs anti-scalant for chloride and water reduction practice
24PRETREATMENT & FILTRATION | Water Treatment Boot Camp
KEYTAKEAWAYS
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Cooling TowersFunctionGeneral DesignWater Treatment
Presenter:Jeff Freitag – Director of Sales
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Cooling TowersWhat is the purpose of a cooling tower?• Reduce water usage/ recycle water
Types of cooling towers• Induced draft
• Forced Draft
26COOLING TOWERS | Water Treatment Boot Camp
The Life Blood of the Plant
Approximately 70% of a plants water use is for cooling, 20% for process and 10% for other uses.
Cooling towers provide the most efficient means of rejecting heat from open recirculating cooling water systems.
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What Processes do you have that require cooling water?• Chillers
• Heat exchangers
• How do they work?
28COOLING TOWERS | Water Treatment Boot Camp
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Chilled Water LoopsConcerns with Chilled Water Loops• Corrosion• Scale (less likely)• Particulate•Microbiological growth
What is important to protecting chilled water loops?• Corrosion inhibitor• Filtration• Biocide
31COOLING TOWERS | Water Treatment Boot Camp
Basic Water Chemistry –Cooling Towers
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Basic Water Treatment Components• Make up and blowdown water meters
• Blowdown/Bleed valve
• Conductivity, Evirodose (ptsa), pH, ORP control
• Inhibitor pump
• Biocide pumps
• Optional• Tanks, level sensors, flow meters
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Cooling System Overview
COOLING TOWERS | Water Treatment Boot Camp
The Process of Evaporative Cooling
35COOLING TOWERS | Water Treatment Boot Camp
• Circulating cooling water, after picking up heat from the process heat exchangers , passes through the tower.
• Evaporation provides most of the cooling as the recycled water passes through the tower.
• As a result of evaporation, the dissolved solids in the water become concentrated.
• The rate of water discharge, blowdown, stabilizes the dissolved solids content of the water.
• The evaporative process also absorbs gasses from the air, particulate matte, nutrients - for biological growth-and reduces the solubilities of the solids remaining in the circulating water.
Typical Sources of Cooling Tower Make Up• Well water - scaling
• Municipal source water - scaling
• Waste water -scaling, corrosive, fouling
• Reuse water (RO concentrate) - Scaling
• Process condensate (cow water) – corrosive, fouling
• Each poses different challenges• Pretreatment may or may not be necessary• Each source of water will pose unique challenges
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Soft Water and Filtration
37COOLING TOWERS | Water Treatment Boot Camp
Pros vs. Cons of using soft water for cooling water makeup?◦ Lake Michigan vs. Waukesha water◦ Safety
What kind of Filtration should you use?
Cooling Tower Water Treatment Goals
38COOLING TOWERS | Water Treatment Boot Camp
Public Health and Safety
Cycles of Concentration
BLEE
D RA
TE
1 2 3 4 5 6 7 8 9 10 11
Control Fouling and Corrosion
Minimize Water Usage
Cycles of ConcentrationBoilers and Cooling Towers
• Build-up of the concentration of dissolved solids in recirculating water = “cycling up”
• Determine the maximum number of cycles of concentration to run w/o forming deposits or causing excessive corrosion• Your Water Treatment Supplier is responsible for this.
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What Cycling Means
COOLING TOWERS | Water Treatment Boot Camp
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How To Control Cycles In Your Tower
COOLING TOWERS | Water Treatment Boot Camp
Water Use and Your Recirculating Cooling Water System
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43COOLING TOWERS | Water Treatment Boot Camp
Before: Tower at 3 Cycles
AnnualMake Up
AnnualBleed
22.86 MG 7.56 MG
$43,094 $19,656
3,000 GPM Recirc Rate
30 GPM
15 GPM 45 GPM
400 uS
Controller
Setpoint
= 3 Cycles
1,200 uS
10oF T
Make Up
Evaporation
44COOLING TOWERS | Water Treatment Boot Camp
After: Tower at 5 Cycles
AnnualMake Up
AnnualBleed
19.15 MG 4.03 MG
$36,389 $10,483
3,000 GPM Recirc Rate
30 GPM
8 GPM 38 GPM
400 uS
Controller
Setpoint
2,000 uS
= 5 Cycles 10oF T
Make Up
Evaporation
Summary of Cooling Scenarios
45COOLING TOWERS | Water Treatment Boot Camp
Make Up Flow Make Up Cost Bleed Flow Bleed Cost
3 Cycles 22.86 MG $43,094 7.56 MG $19,656
5 Cycles 19.15 MG $36,389 4.03 MG $10,483
SAVINGS 3.71 MG $7,514 (-15.5%)
3.52 MG $9,173(-46.7%)
Chemical / Misc Savings = >$10,000 per year
TOTAL SAVINGS = $27,000 per year
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Effective Ways to Increase Cycles of ConcentrationRecirculating Cooling Tower
1. Automate chemical feed and tower bleed
2. Soften the makeup water
3. Feed acid to control alkalinity and pH
4. Look for a better source of makeup water
5. Install “side-stream” filtration for solids removal
46COOLING TOWERS | Water Treatment Boot Camp
Cooling Water Problem Areas
47
Cooling Water System Problem Areas
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• Scale – calcium, magnesium, iron, silica
• Corrosion – loss of metal
• Fouling◦ M icrobiological – bacteria, mold, fungus, algae◦ W ind blown debris, process contamination
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Cooling Water System Problem Areas
SCALING
CORROSION
FOULING
COOLING TOWERS | Water Treatment Boot Camp
Basic Cooling Water Treatment Programs• Scale and corrosion inhibitor blend
• Biocides• Oxidizing• Non-oxidizing biocide
• Anti-foulants
50COOLING TOWERS | Water Treatment Boot Camp
Scale and Corrosion Inhibitor• Blend of polymers, sequestrants, dispersants and
corrosion inhibitors• Specific blends to handle various water qualities and
contamination issues
• Feed with or without acid• Acid for alkalinity reduction
• Soft water makeup – corrosion control issue
• Lab and direct measurement tests for monitoring• PTSA, polymer, phosphonate, molybdenum
• Feed proportional to makeup/bleed volume or direct measurement
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Microbiological ControlBiocides to control bacteria, mold, fungus, algae• Inhibit heat transfer• Inhibit flow• Increase corrosion – “mic” =
microbiologically induced corrosion
• Health and safety issue –Legionella
52COOLING TOWERS | Water Treatment Boot Camp
BiocidesOXIDIZING
1. Dosage is based on system volume
2. Different biocides have different requirements• pH, ammonia, retention time, organics
3. Requirements for effectiveness• Correct concentration
• sufficient contact time
4. Dual Biocide Program works best
53COOLING TOWERS | Water Treatment Boot Camp
BiocidesOXIDIZING
• Chlorine
• Bromine
• Chlorine dioxide
• Hydrogen peroxide, peracetic acid
54COOLING TOWERS | Water Treatment Boot Camp
NON-OXIDIZING
• Isothiazolone
• Gluteraldehyde
• DBNPA
• Quaternary amine
• Many more
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The Cooling System… What to knowConductivity control is critical to proper water chemistry • Use automation to accomplish this• Check calibration with hand held conductivity meter
Maintain proper scale and corrosion inhibitor levels• Envirodose automation, op testing and others.
Ensure biocides are being fed as prescribed• Track ORP for oxidizing biocide.• Monitor tank levels, pump flow of non-oxidizing biocides.
If pH control is in use, automated control of acid pump with pH sensor is a must!• Check calibration with hand held pH meter.• Run total alkalinity test as a back up test.
Install water meters to track make up and blowdown gallons
55COOLING TOWERS | Water Treatment Boot Camp
5 Key Cooling Takeaways –To Reduce Cost1. Know your water and be committed to your water management
program.
2. Know your pretreatment equipment and make sure it is operating properly and efficiently.
3. Install make up and blowdown water meters on all of your equipment where applicable. Know where you use and discharge water and how much
4. Understand cycles of concentration to optimize and reduce water, energy, chemical and salt usage.
5. Consider utilizing automated systems to monitor, control, alarm and trend critical water systems.
56COOLING TOWERS | Water Treatment Boot Camp
KEYTAKEAWAYS
Steam BoilersFunctionGeneral DesignChemical Treatment
Presenter:Rob PierickSenior Territory Manager
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Basic Boiler System
STEAM BOILERS | Water Treatment Boot Camp
INPUTS
OUTPUTS
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Boilers
STEAM BOILERS | Water Treatment Boot Camp
What are a boilers worst enemies?
• Scale
• Corrosion
What types of boilers are there?
• Firetube
• Watertube
DeaerationOxygen is a natural component of virtually all water supplies.
At feedwater and boiler temperatures, even small amount of oxygen greatly accelerate corrosion.
Corrosion will typically be observed in a few specific locations.• Economizer - dramatic increase in temperature• Steam drum at steam/drum interface• Condensate system
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Spray Type Deaerator Operation
61STEAM BOILERS | Water Treatment Boot Camp
Purpose of Deaeration• Primary purpose is to remove oxygen and
other dissolved gasses from the feedwater.• Preheat the feedwater to prevent thermal
shock on the boiler
Dissolved gasses that may be removed:• oxygen• carbon dioxide• ammonia• hydrogen sulfide
62STEAM BOILERS | Water Treatment Boot Camp
Dissolved Oxygen Concentration Vs. Water Temperature
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Deaerator Vs. Feedwater TankWhat is the MAJOR difference BETWEEN a deaerator AND A feedwater tank?• Much lower oxygen levels
What ARE the benefits of using a deaerator over a feedwater tank?• Reduce chemical and energy usage,
Reduce expansion and contraction
64STEAM BOILERS | Water Treatment Boot Camp
Chemical DeaerationEffluent from a properly operating deaerator contains no more than 7 ppb oxygen.
Last traces of oxygen must be chemically scavenged from the feedwater.
Two types of scavengers• Inorganic - Sulfites• Organic - DEHA, Erythorbate, etc.
65STEAM BOILERS | Water Treatment Boot Camp
Basic Boiler Treatment Programs1. Oxygen scavenger – corrosion control
2. Internal treatment program – deposit control
3. Condensate treatment – corrosion control
4. Miscellaneous – alkalinity builders, antifoam
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Typical Boiler System Chemical Feed Points
STEAM BOILERS | Water Treatment Boot Camp
Internal Treatment &
Alkalinity Builders
Make Up Condensate
Feed Water
Blowdown
Controller
Steam
Condensate
Treatment
Oxygen Scavenger
Internal
Treatment
Heat Exchanger
Oxygen Scavengers
68STEAM BOILERS | Water Treatment Boot Camp
• Sulfite• DEHA, Erithorbate, hydrazine• Feed to storage section of the DA / Feedwater
tank below the water line
• Maintain a constant residual of oxygen scavenger
O2 Scavenger Performance Monitoring
69STEAM BOILERS | Water Treatment Boot Camp
• Monitor your DA / feedwater tank pressure and temperature
• Watch scavenger concentrations
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Internal Treatments
70STEAM BOILERS | Water Treatment Boot Camp
Internal Deposit Inhibitor• Blends of polymers, dispersants, sequestrants, phosphate, chelants• Control of deposits of hardness scales, iron, copper, silica• Feed point varies depending on the treatment program and water quality
• Various test methods to determine actual concentration in boiler water
Recommendations• Don’t rely on internal treatment to do all the work
• Properly operated Pretreatment equipment is critical
Condensate Line Corrosion Control
71STEAM BOILERS | Water Treatment Boot Camp
Carbonic Acid Attack – Low pH• From makeup water alkalinity ---- carbon dioxide = C02
• Remove the carbonate alkalinity in the makeup - proper pretreatment
Oxygen Attack
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Steam / Condensate Treatments
STEAM BOILERS | Water Treatment Boot Camp
Carbonic Acid Attack – Low pH◦ Volatile Amines used to raise the pH of condensate to prevent acidic attack◦ Usually a blend of 2-4 different amines that provide total system coverage
Oxygen Attack• used to prevent oxygen corrosion from air intrusion into condensate system
CO2
Alkalinity
Amine + VOS
Oxygen
CO3
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Oxygen Control in Condensate Systems
• Enters through condensate receivers, vacuum pumps, process systems
• Treated using volatile oxygen scavengers (V.O.S.) such as DEHA, hydroquinone, Mekor, and filming amines
• Blended amines and V.O.S.
73STEAM BOILERS | Water Treatment Boot Camp
• Watch iron and copper concentrations
• Monitor pH levels because low pH levels and oxygen accelerate corrosion rates
• Monitor VOS concentration
CAUSES AND TREATMENTS MONITORING
Water Use and Your Boiler Water System
74STEAM BOILERS | Water Treatment Boot Camp
Cycles of ConcentrationBoilers and Cooling Towers
• Build-up of the concentration of dissolved solids in recirculating water = “cycling up”
• Determine the maximum number of cycles of concentration to run w/o forming deposits or causing excessive corrosion• Your Water Treatment Supplier is
responsible for this.
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What Cycling Means
STEAM BOILERS | Water Treatment Boot Camp
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How To Control Cycles In Your Boiler
STEAM BOILERS | Water Treatment Boot Camp
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Make Up Condensate
Feed Water
Blowdown
50,000 #/hrSteaming Rate
Setpoint
3,500 uS
Controller
850 uS
Steam67,925 GPD 92,455 GPD
160,380 GPD
16,495 GPD
360 uS
= 9.7 Cycles
Before58%
AnnualMake Up
AnnualBlowdown
23.77 MG 5.77 MG
$45,170 $15,010
Heat Exchanger
STEAM BOILERS | Water Treatment Boot Camp
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Make Up Condensate
Feed Water
Blowdown
50,000 #/hrSteaming Rate
Setpoint
3,500 uS
Controller
850 uS
Steam32,120 GPD 119,565 GPD
151,686 GPD
7,801 GPD
180 uS
= 19.4 Cycles
After79%
Heat Exchanger
AnnualMake Up
AnnualBlowdown
11.24 MG 2.73 MG
$21,360 $7,098
STEAM BOILERS | Water Treatment Boot Camp
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Make Up Flow Make Up Cost Blowdown Flow Blowdown Cost
9.4 Cycles 23.77 MG $45,170 5.77 MG $15,010
19.7 Cycles 11.24 MG $21,360 2.73 MG $7,098
SAVINGS 12.53 MG $23,810 (-52.7%)
3.04 MG $7,912(-52.7%)
Fuel Savings = $40,000 per year
TOTAL SAVINGS = $92,000 per year125 psi boiler operating at 80% efficiency, 2012 city of Milw. Water cost, $4.50/MSCF gas cost, 160oF condensate temp.,
Chemical Savings = $20,000 per year
STEAM BOILERS | Water Treatment Boot Camp
Hot Water Boilers and Loops• Common for comfort heating applications and smaller processes in plants
• What is important to protecting the hot water boiler and piping system?
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Key Takeaways – Boilers• Feedwater hardness test is the most critical test to run and keep in range
• Conductivity control is critical to proper water chemistry• Use automation to accomplish this
• Maintain proper oxygen scavenger levels• Check deaerator, chemical feed pump, tank levels if readings are low
• Maintain proper levels of internal treatment/dispersant• Adjust chemical feed pump as needed
• Track condensate and feedwater total iron levels to monitor for corrosion byproduct concentration.
• Track condensate pH to ensure proper feed of steam and condensate treatment
82STEAM BOILERS | Water Treatment Boot Camp
KEYTAKEAWAYS
Water Testing TechniquesSamplingWork StationTesting Techniques
Presenter:Rob PierickSenior Territory Manager
83
General Sampling TechniquesA good sampling container• Preferably with a handle to minimize exposure to water
Wear gloves• Some of the reagents are not nice• Phenolphthalein is a carcinogen. It was a laxative first…
Always rinse the sample bottle 3 times• This removes contaminants• Both sampling bottles and test vials and cuvettes
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Where to Grab Boiler System Samples
WATER TESTING TECHNIQUES | Water Treatment Boot Camp
Boiler System Sampling
86WATER TESTING TECHNIQUES | Water Treatment Boot Camp
Sample Cooler• Provides a safe, cooled sample• Important for temperature sensitive tests• Sulfite, condensate
• A necessity on high pressure systems
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Testing Procedures Review – Digital
88WATER TESTING TECHNIQUES | Water Treatment Boot Camp
Fluorometry• Uses the fluorescence of an activated
tracer to determine concentrationInterferences• Oil in water
• Color in sample prior to readingEnvirodose• Boiler
• Cooling• Closed Loop
Digital• Multiple tests available
• Easy to read results
• Math rarely needed
• Must keep glass clean
• Requires reagents
Testing Procedures Review – Drop Test
89WATER TESTING TECHNIQUES | Water Treatment Boot Camp
Reagent based test• Relies on chemical reaction in sample to show endpoint
Low initial costInterferences
• Iron, pH, oxidizers, temperature
Wide range of options• Hardness, OPO4, Sulfite, alkalinity, etc
Considerations• Always hold dropper bottle straight up and down• Dropper bottles are calibrated for 0.1mL per drop
• Make sure sample cell used is rinsed 3 times
Testing Procedures Review – Titration
90WATER TESTING TECHNIQUES | Water Treatment Boot Camp
Reagent based test• Relies on chemical reaction in sample to show endpoint
Least expensive overall considering reagent costs• Larger upfront cost then drop tests
Interferences• Iron, ph, oxidizers, temperature
Less options but used mainly for basic tests• Hardness, sulfite, alkalinity, chlorides
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Water Testing
91WATER TESTING TECHNIQUES | Water Treatment Boot Camp
Break into teams and test for:• Total Hardness• Conductivity
Troubleshooting & Corrective Actions
Presenter: Jeff Freitag – Director of Sales
92
Corrective Actions
93TROUBLESHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
• Identify parameters out of range and the potential cause• Chemical vs mechanical-based corrections • Corrective action follow-up
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Corrective Actions
94TROUBLESHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
So you know what to sample, where to grab the sample, how to make sure it’s a good sample, how to run the proper test, and where to log the reading…
Now what?
Before you do anything…
95TROUBLESHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
Re-sampleRe-rinseRe-test!
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Trouble Shooting & Corrective ActionsPRETREAMENT
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Filters – Corrective Actions
Most common Problems with filters:• High pressure loss• Improper application• Improper micron rating• Plugging / fouling /
labor intensive
97TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
Filters – Corrective Actions
Most common Problems with filters:• Plugging / fouling / labor intensive• Contamination• Poor water treatment• Start up•Microbiological issues
98TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
Softeners – Corrective Actions
99
Most common Problems with water softeners:• No Salt• Improper programming• Improper sizing
• Bad seals or internals
What to check:
• Re-run sample (flush)• Test right after online unit• Check status of unit online
• Check brine tank• Switch softeners / put into regen
TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
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How do you know the softener is working?
100
• Perform a total hardness test on the water.
• Soft water used for boiler make up should have <0.5 ppm of total hardess. This will vary depending upon boiler pressure. As pressure goes up acceptable hardness levels go down.
• Soft water used for cooling tower make up should be less than 20 ppm as a rule of thumb. This value should go down as the cycles of concentration in the tower go up.
TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
Troubleshooting Softeners
101
Short Runs ◦ Change in raw water hardness
◦ Poor regeneration◦ Resin Fouling◦ Loss of resin
High Hardness◦ Raw water bypassing unit
◦ Resin fouling◦ Increased raw hardness in supply water
High Pressure Drop◦ Bed fouling
◦ Poor backwash◦ Plugged under drain◦ Deteriorating Resin
TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
Brine Elution Studies• Problems in zeolite softener systems are often due to poor regeneration practices.
• Brine elution study is often used to troubleshoot this process.• Plots the concentration of brine from a zeolite softener during regeneration using a brine salometer and
graduated cylinder
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Elution Studies
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Reverse Osmosis Corrective Actions
104
Most common Problems with water RO’s:• Hardness coming from softener
• Chemical feed to the ro• Pre-Filters plugging
• Bad seals• Poor pressure from pump• Chorine breakthrough
• Due for cleaning
TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
Reverse Osmosis Corrective Actions
105
If hardness or conductivity are high:
• Check the quality of the influent water first
• Check all gauges
• Check water quality on outlet of each membrane
TROUBLE SHOOTING & CORRECTIVE ACTIONS | Water Treatment Boot Camp
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Monitoring and Maintenance• Ensure that the system is operating properly.
• Determine if gradual fouling, scaling or membrane degradation is occurring by observing system performance over time.
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Trouble Shooting & Corrective ActionsBOILERS
Determining Proper Control Ranges• Control Ranges
- ASME for boilers
• Boiler Plate
• Limiting factors- Iron- Silica
• EXPERIENCE!!
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ASME Boiler Guidelines
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American society of mechanical engineers (ASME)
& American boiler manufacturer (ABMA) Guidelines
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Water Testing – Test Procedure Guidelines
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SAMPLETotal
HardnessCalcium
HardnessP
Alk.M
Alk.TDS,
mmhoOrgano
Phos SulfiteTotal
Polymer pHTotalIron
RAW WATER X X X X XSOFT WATER X X
RO PERMEATE X X XFEEDWATER X X X X X X
CONDENSATE X X X XBOILER WATER X X X X X
COOLING TOWER X X X X X X
Boiler Control Chart
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Test Range Corrective Actions
Total Polymer(PP-3060M)
.6-.8
• If out of range, check conductivity of the boilers. High or low conductivity will cause high or low readings.
• If conductivity is okay, increase addition of PP-3060M if polymer is low, decrease if polymer is high.
Sulfite(WT-3462) 20-40 ppm
• Check deaerator temperature.• Check conductivity in the boilers.• If both are in range, increase feed of WT-3462 if
the reading is low and decrease the feed of the WT-3462 if the reading is high.
Alkalinity(WT-3732)
P= 300-400M= 350-650OH=200-400
• Check conductivity levels. High or low conductivity will cause high or low alkalinity.
• Check for proper feed of the WT-3732 sodium hydroxide.
• If both are correct, increase the feed of the WT-3732 to increase alkalinity levels and decrease the pump to decrease alkalinity levels.
Total Hardness(Softeners, Feedwater &
Condensate)<.5 ppm
• If hardness if present, check the softeners and condensate for possible contamination.
• Regenerate softener on line if necessary.
Boiler Conductivity(Un-Neutralized)
mmho1,800-2,300
• If conductivity is out of range, check operation of blowdown controllers.
• Calibrate as necessary
pH(WT-3516)
8.3 – 8.8
• Increase feed of the WT-3516 if pH is low. Decrease feed if pH is high.
• Wait for two days of below 8.0 readings to increase feed of the WT-3516
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Boiler Log Sheet
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Deaerator Corrective ActionsMost common problems:• Temp/pressure not correlating
• Chemistries out of range
• Contamination
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Deaerator Corrective ActionsIf the temperature/pressure is low:
• Check pressure
• Check accuracy of gauges
• Check vent
• Check steam heating system
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Troubleshooting Deaerators
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Deaerator performance is monitored with a dissolved oxygen analyzer and Chemetrics tests.
If effluent level of oxygen is high:• Check pressure and temperature for insufficient steam flow.• Check vent valve - Should have 18” plume
• Poor spray pattern - Check spray system• Broken scrubber or trays - Inspect
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Deaerator Vents
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Boiler Corrective ActionsMost common problems:
• Conductivity out of range• Chemistries out of range
• Cloudy / colored water• Boiler water carryover
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BoilerProblemB1 Low Conductivity, Alkalinity & Sulfite:• Re-run sample (flush)• Check for loss of
water or improperly operating blowdown system
• Normal???
High pH:• Related to poor boiler
readings?
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BoilerResultB1 Low Conductivity, Alkalinity & Sulfite:• Normal
• Lead/Lag program
High pH:
• Most likely steam line treatment overfeed
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BoilerProblemB1 High Sulfite:• Where is
conductivity?• Compare to 2nd boiler
Low conductivity:• Check for loss of
water or improperly operating blowdown system
• Check lead/lag operation?
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BoilerResultB1 High Sulfite:
• Since conductivity is low, this is likely an overfeed. Same on B2.
Low conductivity:
• Check lead/lag operation
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BoilerProblemLow Conductivity:
• Related to operation?
• What about probe temperature?
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BoilerResultLow Conductivity:
• Always check the blowdown valve first.
• Check all blowdown piping to see if it is hot.
• Check bypass around
blowdown valve.• Check for internal
leaks.
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Check position of valve/stem
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Boiler Blowdown Valve
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Boiler Blowdown Valve
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BoilerProblemB2 Low Sulfite:
• Related to high conductivity?
• Related to low phosphate?
Condensate pH high:• Related to other
readings?
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BoilerResultB2 Low Sulfite:
• No chemical getting into boiler FW tank!
Condensate pH high:
• Not related to anything else. Just an overfeed.
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WTH?
Never hesitate to question everything!
This was the sulfite chemical.
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Condensate ProblemIntermittent High
Hardness:
• Related to boiler Water?
• Related to conductivity?
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Condensate Result B2 Low Sulfite:
• No chemical getting into boiler FW tank!
Condensate pH high:
• Not related to anything else. Just an overfeed.
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Steam and Condensate – Corrective ActionsMost common problems:
• Conductivity high• pH high or low
• Total hardness high• Iron detected
• Cold condensate
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Steam and Condensate – Corrective ActionsSlightly Elevated Hardness:
• Check individual return lines• Check conductivity levels
• Try to find specific source• Most likely bad heat
exchanger
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Trouble Shooting & Corrective ActionsCOOLING
Determining Proper Control Ranges• LSI, RSI indexes for cooling towers
- Fouling vs. Biocide rates- CTI?/ASHRAE
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Tower Control Chart
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Test Range Corrective Actions
Total Hardness 20 – 80 ppm • If hardness is present, check the softeners.• Regenerate softener on line if necessary.
Free Chlorine .2 – 1.0 ppm• If levels are out of range check to see that the pump is primed and pumping.• Check conductivity levels. High or low conductivity will cause high or low free chlorine
levels.
Cooling Tower Conductivity 2,800 – 3,000• If conductivity is high, check the operation of the blowdown solenoid.• If conductivity is low, check for uncontrolled losses or overflow of the sump.• Verify the controller is reading properly. Calibrate or replace the sensor if needed.
PTSA Tracer(CWT-766)
150 – 200 ppb
• If levels are out of range check to see that the pump is primed and pumping.• Check conductivity levels. High or low conductivity will cause high or low conductivity will
cause high or low molybdenum levels.• Check to see that the makeup water meter is turning and registering flow.
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Cooling Tower Log Sheet
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Cooling Tower – Corrective ActionsMost common problems:
• Conductivity out of range• Inhibitor out of range
• Microbiological activity• Sediment and/or algae noticed in tower
• Automation issues
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Cooling Tower – ProblemHigh Bacteria:
• Check conductivity level
• Check sediment build up in tower
• Check that the biocide pumps are primed
• Check for chemical in the tanks
• Turn up feed rate • Test for proper biocide residuals
• Retest bacterial levels in one week
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Cooling Tower – ResultHigh Bacteria:
• Check sediment build up in tower
• Turn up feed rate
• Test for proper biocide residuals
• Retest bacterial levels in one week
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Cooling Tower – ProblemPTSA (inhibitor) Sensor Issues:
• PTSA Sensor is acting up
• Calibrated several times
• Replaced w/ new sensor
• Read perfect for 3 hours
• Dropped to near zero and stayed
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80 pts out of spec
In range
Flat line
Cooling Tower – ResultPTSA (inhibitor) Sensor Issues:
• Wiring was fine
• There was chemical in the system
• Flow across sensor is good
• Faulty sensor out of the box!
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Problem: Envirodose Inhibitor levels dropping
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Result: Bad Pump. Diaphragm failed and was leaking out of the weep hole.
Cooling Tower – Corrective Actions
Low or no chemical in tank.
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Cooling Tower – Corrective Actions
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Clean Sensors
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Flow Meters
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Strainers
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Healthy ORP vs 5213 usage graph
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Problem: ORP drops – 5213 feed
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Bad Diaphragm
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Low ORP with Normal Chemical Feed
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Chlorine Degradation
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Trouble Shooting & Corrective ActionsEXERCISE HAND-OUTS
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Tower ExerciseProblem
Low Molybdenum/Inhibitor:• Check conductivity level
• Check log book for
trending data
• Check that pump is primed
• Check for chemical in the
tank
• Turn up the feed rate
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Tower ExerciseResult
Low Molybdenum/Inhibitor:• Turn up the feed rate
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Tower ExerciseProblemHigh Conductivity:• Check operation of bleed
valve
• Check flow to drain when bleed valve is open
• Check conductivity sensor
• Run graph on bleed meter
vs. makeup meter
Tower Exercise ResultHigh Conductivity:
• Valve would only open partially• Actuator was bad. Ordered a new
one.
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BoilerExerciseProblem– DeaeratorLow pH:• Check makeup water
quality
• Check condensate return water quality
• Check chemical feed levels
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BoilerExerciseResult– DeaeratorLow pH:• Check prime on pump
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Pump That Has Lost Prime
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BoilerExerciseProblem B4 High Polymer:
• Related to Conductivity?
• Compare to 2nd boiler• Chemical overfeed?
Low conductivity:• Lead/Lag?
• Lag boiler taking on condensate?
• Water Loss?
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BoilerExerciseResult
B4 High Polymer:
• Chemical overfeed
Low conductivity:• Water Loss
Equipment & Reporting
Presenter: Rob Pierick – Territory Manager
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Controllers
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Controller Installation – What Not to do.
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Controller Installation• All components located in one location• Easy to access
• Isolation valves• Quick release sensors
• Sample/drain valve• Wiring
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Types of Chemical Feed Pump – DiaphragmAdvantages• Wide range of capacity and pressure• Wide range of compatibility
• Proven design
Disadvantages• Can get air locked
• Can struggle with high viscosity products
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Types of Chemical Feed Pump – PeristalticAdvantages• Good for thick products• Naturally degassing
• No loss of prime
Disadvantages• Tube life
• Pressure ratings• Compatibility
• Messy when tube fails
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Chemical Feed Pump Installation
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Flooded Suction (Ideal) Tank/Drum Mount (Most Common)
Chemical Feed Pump Operation & Maintenance
Loss of prime• Degassing product
• Loose connections• Cracked suction tubing
Leaks• Incompatible tubing
• Old tubing• Loose connections
• Plugged injectorSiphoning
• No back pressure
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Valve Selection CriteriaRule 1: No Solenoids!
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Valve Selection Criteria – Type
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Valve Installation – Boiler Blowdown
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Cooling Tower Bleed ValveValve Installation
• Keep bleed line as short as possible.
• Eliminate pipe bends and reductions in pipe size.
Operation & Maintenance
• Internal limit switch failure
• Plugging
• Leaking
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Water Meters
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Water Meter Basic Application
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Meter Type Positive Displacement
Inline Turbine Insertion Paddlewheel
Ultrasonic
Cooling Tower and Boiler Makeup
Boiler Feedwater
Cooling Tower Bleed
Process Water
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Monitoring & ReportingController Data• System optimization• Root cause analysis
Manual Data• Assist in operator training• Identify automation problems
Advanced Metrics• Cycles of concentration• Tons of Cooling• Water usage• Cost of treatment
System Performance Measurement
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Key Takeaways – Equipment• Considering all inputs and outputs (current and future)
• Pumps• Materials compatibility• Flow and pressure requirements
• Viscosity
• Valves• Size, pressure and temperature
• Flow Meters• Type of water (clean/dirty, temperature)
• Installation location and configuration
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KEYTAKEAWAYS
EQUIPMENT & REPORTING | Water Treatment Boot Camp
Questions?
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